Bra cup for a brassiere and manufacturing method thereof

ABSTRACT

A bra cup for a brassiere to be worn by a wearer is disclosed. The bra cup comprises a core layer. The core layer has an inner side and an outer side. A plurality of apertures are formed in the core layer. In one example, one or more of the plurality of apertures have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side. In another example, the plurality of apertures comprises a plurality of elongated apertures formed in a frontal area of the bra cup and a plurality of circular apertures formed in a lateral area of the bra cup. The plurality of elongated apertures have a dumbbell shape. In yet another example, the bra cup comprises a plurality of protrusions defined in the core layer towards the inner side thereof.

FIELD OF THE PRESENT DISCLOSURE

The present disclosure generally relates to brassieres, and inparticular to a bra cup for the brassiere having means to provide airpermeability and allow for dissipating heat from the skin of the wearerwhen the brassiere is worn.

BACKGROUND

Typically, a bra cup for a brassiere includes a pad along with thefabric layer therein. The pad is located normally covering the entirebreast cup regions of a bra. These pads are normally made from a foammaterial and is incorporated between interior and exterior most layersof the bra. Pads that are incorporated in bras can help support thebreasts and also create uplift. The pad also provides the flexibility toadapt the bra cup to conform to shape of a breast of a wearer.Traditionally, such pads are manufactured by compression moldingprocess, in which a preformed solid foam form is created into a bra cupshape. However, the use of compression molding process has somedisadvantages. The pad formed by using such process may generally haveinconsistent densities along various section; for example, thicksections may have generally higher densities and thin sections may havecomparably lower densities. Also, the use of foam pad may reduce the airpermeability of such bra cups and thus makes the brassiere uncomfortableto wear for a long duration of time. Moreover, the use of foam pads mayresult in large surface area of inner side of the bra cup to be disposedin contact with the skin of the wearer which negatively affect the heatdissipation therefrom. Furthermore, such compression molding processmakes it difficult to define or form any structures or shapes in suchpads, to provide certain characteristics to the brassiere.

Accordingly, there is a need of a bra cup with means which provide highair-permeability and allow for dissipating heat so as to providecomfortable experience for the wearer when the brassiere is worn.

SUMMARY

In one aspect, a bra cup for a brassiere to be worn by a wearer isdisclosed. The bra cup comprises a core layer formed of a foam materialand having a three-dimensional configuration so as to conform to abreast of the wearer when the brassiere is worn. The core layer has aninner side and an outer side. A plurality of apertures are formed in thecore layer. In the bra cup, one or more of the plurality of apertureshave a truncated conical cross-section with a relatively larger diametertowards the inner side and a relatively smaller diameter towards theouter side.

In one embodiment, the plurality of apertures comprises a plurality ofcircular apertures formed in a lateral area of the bra cup. One or moreof the plurality of circular apertures in a lower portion of the lateralarea have the truncated conical cross-section.

In one embodiment, the plurality of apertures comprises a plurality ofelongated apertures formed in a frontal area of the bra cup. One or moreof the plurality of elongated apertures have a dumbbell shape with aslit and two openings formed at two ends of the slits respectively.

In one embodiment, the bra cup further comprises a plurality ofprotrusions defined in the core layer towards the inner side thereof.The protrusions are arranged in a matrix form such that one or more ofthe plurality of apertures are surrounded by three or more protrusionsat the inner side of the core layer.

Preferably, the plurality of protrusions comprises a first set ofprotrusions with substantially square shape and a second set ofprotrusions with substantially parallelogram. The first set ofprotrusions are located in a frontal area of the bra cup and the secondset of protrusions are located in a lateral area of the bra cup.

Preferably, the core layer and the plurality of apertures are formed byan injection molding process.

Preferably, the bra cup further comprises a mesh joined with the corelayer in the injection molding process.

Preferably, the bra cup further comprises an underwire embedded withinthe core layer.

Preferably, the underwire is made either of metallic material or plasticmaterial.

In one or more embodiments, the bra cup further comprises an inner layercomprising at least a fabric sheet and optionally a foam sheet, andarranged with respect to the core layer such that the inner layer isdisposed to be in contact with the breast of the wearer, when thebrassiere is worn; and an outer layer comprising at least a fabric sheetand optionally a foam sheet, and arranged with respect to the core layersuch that the outer layer is located at a distal end from the breast ofthe wearer, when the brassiere is worn.

In another aspect, a method of manufacturing a bra cup for a brassiereis disclosed, the method comprises providing a foam material in liquidform. The method further comprises providing a mold arrangementcomprising a first mold and a second mold. At least one of the firstmold and the second mold have a plurality of projections definedtherein. The method further comprises injecting the foam material intothe mold arrangement between the first mold and the second mold. Themethod further comprises curing the foam material to be contoured into athree-dimensional configuration to form a core layer of the bra cup witha plurality of apertures, complementary to the plurality of projections,formed therein.

Preferably, the plurality of apertures comprises a plurality ofelongated apertures disposed in a frontal area of the bra cup and aplurality of circular apertures disposed in a lateral area of the bracup.

Preferably, one or more of the plurality of elongated apertures have adumbbell shape with a slit and two openings formed at two ends of theslits respectively.

Preferably, one or more of the plurality of circular apertures in alower portion of the lateral area have a truncated conical cross-sectionwith a relatively larger diameter towards an inner side of the corelayer and a relatively smaller diameter towards an outer side of thecore layer.

Preferably, the method further comprises providing a mesh; andsupporting the mesh on one or more first anchors between the first moldand the second mold during the injection of the foam material, such thatthe mesh is joined with the core layer from at least one of an innerside and an outer side thereof when the foam material is cured.

Preferably, the method further comprises providing an underwire; andsupporting the underwire on one or more second anchors between the firstmold and the second mold during the injection of the foam material, suchthat the underwire is embedded within the core layer when the foammaterial is cured.

Preferably, the method further comprises providing a fabric sheet whichis to be part of an inner layer of the bra cup; and providing a fabricsheet which is to be part of an outer layer of the bra cup, such thatthe foam material is injected between the fabric sheet of the innerlayer and the fabric sheet of the outer layer such that the formed corelayer is joined therewith when the foam material is cured.

In yet another aspect, a bra cup for a brassiere to be worn by a weareris disclosed. The bra cup comprises a core layer formed of a foammaterial and having a three-dimensional configuration so as to conformto a breast of the wearer when the brassiere is worn. The bra cupfurther comprises a plurality of apertures formed in the core layer. Theplurality of apertures comprises a plurality of elongated aperturesformed in a frontal area of the bra cup and a plurality of circularapertures formed in a lateral area of the bra cup.

Preferably, one or more of the plurality of elongated apertures have adumbbell shape with a slit and two openings formed at two ends of theslits respectively, such that each of the one or more of the pluralityof elongated apertures allows for expansion of the core layer along adirection substantially orthogonal to a direction of extension of thecorresponding slit therein.

Preferably, one or more of the plurality of circular apertures in alower portion of the lateral area have a truncated conical cross-sectionwith a relatively larger diameter towards an inner side of the corelayer and a relatively smaller diameter towards an outer side of thecore layer.

In still another aspect, a bra cup for a brassiere to be worn by awearer is disclosed. The bra cup comprises a core layer formed of a foammaterial and having a three-dimensional configuration so as to conformto a breast of the wearer when the brassiere is worn. The core layer hasan inner side and an outer side. The bra cup further comprises aplurality of apertures formed in the core layer. The plurality ofapertures are extending between the inner side and the outer side of thecore layer. The bra cup further comprises a plurality of protrusionsdefined in the core layer towards the inner side thereof. Theprotrusions are arranged in a matrix form such that one or more of theplurality of apertures are surrounded by three or more protrusions atthe inner side of the core layer.

Preferably, the plurality of protrusions comprises a first set ofprotrusions with substantially square shape and a second set ofprotrusions with substantially parallelogram. The first set ofprotrusions are located in a frontal area of the bra cup and the secondset of protrusions are located in a lateral area of the bra cup.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the drawings and the followingdetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of example embodiments of the presentdisclosure, reference is now made to the following descriptions taken inconnection with the accompanying drawings in which:

FIG. 1 illustrates a diagrammatic perspective view of a brassiereincorporating a bra cup, in accordance with one or more embodiments ofthe present disclosure;

FIG. 2A illustrates a diagrammatic perspective view of the bra cup, inaccordance with one or more embodiments of the present disclosure;

FIG. 2B illustrates a partial side view of the bra cup along with azoomed-in portion thereof, in accordance with one or more embodiments ofthe present disclosure;

FIG. 3A illustrates a front view of a core layer of a bra cup region ofthe brassiere, in accordance with a first embodiment of the presentdisclosure;

FIG. 3B illustrates a back view of the core layer of the bra cup regionof the brassiere, in accordance with the first embodiment of the presentdisclosure;

FIG. 3C illustrates a cross-section view of the core layer taken along aline A-A′ of FIG. 3A, in accordance with the first embodiment of thepresent disclosure;

FIG. 4A illustrates a front view of the core layer of the bra cup regionof the brassiere, in accordance with a second embodiment of the presentdisclosure;

FIG. 4B illustrates a back view of the core layer of the bra cup regionof the brassiere, in accordance with the second embodiment of thepresent disclosure;

FIG. 5A illustrates a front view of the core layer of the bra cup regionof the brassiere, in accordance with a third embodiment of the presentdisclosure;

FIG. 5B illustrates a back view of the core layer of the bra cup regionof the brassiere, in accordance with the third embodiment of the presentdisclosure;

FIG. 6A illustrates a front view of the core layer of the bra cup regionof the brassiere, in accordance with a fourth embodiment of the presentdisclosure;

FIG. 6B illustrates a back view of the core layer of the bra cup regionof the brassiere, in accordance with the fourth embodiment of thepresent disclosure;

FIG. 6C illustrates a cross-section view of the core layer taken along aline B-B′ of FIG. 6A along with a zoomed-in portion thereof, inaccordance with the first embodiment of the present disclosure; and

FIG. 7 illustrates a diagrammatic view depicting a molding arrangementfor manufacturing the core layer with a shape of the bra cup definedtherein, in accordance with one or more embodiments of the presentdisclosure.

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of the present disclosure. It will be apparent, however,to one skilled in the art that the present disclosure can be practicedwithout these specific details. In other instances, apparatuses andmethods are shown in block diagram form only in order to avoid obscuringthe present disclosure.

Reference in this specification to “one embodiment” or “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the present disclosure. The appearance of the phrase “in oneembodiment” in various places in the specification are not necessarilyall referring to the same embodiment, nor are separate or alternativeembodiments mutually exclusive of other embodiments. Further, the terms“a” and “an” herein do not denote a limitation of quantity, but ratherdenote the presence of at least one of the referenced item. Moreover,various features are described which may be exhibited by someembodiments and not by others. Similarly, various requirements aredescribed which may be requirements for some embodiments but not forother embodiments.

The embodiments are described herein for illustrative purposes and aresubject to many variations. It is understood that various omissions andsubstitutions of equivalents are contemplated as circumstances maysuggest or render expedient, but are intended to cover the applicationor implementation without departing from the spirit or the scope of thepresent disclosure. Further, it is to be understood that the phraseologyand terminology employed herein are for the purpose of the descriptionand should not be regarded as limiting. Any heading utilized within thisdescription is for convenience only and has no legal or limiting effect.

Where reference herein is made to interior and exterior or similarterminology in relation to component parts or items of the bra or partof the bra, it is meant to be understood to be in relation to the bodyof the wearer of the bra. For example, the “interior” or “inner side” or“inner region” is a relative term to denote that an item is moreproximate the face side of the bra that is more proximate to the body ofthe wearer than items of the bra that are more distal the body of thewearer. “Inner” does not mean “inner most” unless specified. Thissimilarly applies to terms such as “outer” or “exterior”.

Where there is reference to the word “layer” it is to be understood thatit may have its common definition and, but not limited to that the layercould consist of one panel or may have regions that are defined by twoor more panels that are joined and that may each be of a differentcharacteristic (e.g. color, thickness, material, orientation, size).

Referring to the drawings, FIG. 1 illustrates a diagrammatic view of abrassiere 100 (also, sometimes simply referred to as “bra 100”), inaccordance with an embodiment of the present disclosure. In particular,FIG. 1 illustrates a bra cup region 102 of the brassiere 100. Asillustrated, the bra cup region 102 preferably defines two bra cups(both of which are referred by a common numeral 104) that are generallyidentical to each other and are positioned adjacent to each other. Asshown in FIG. 1, the bra cup region 102 may generally be divided intothree areas; a frontal area 102 a of the bra cup 104 (which spans aroundan apex center ‘C’ of the bra cup 104), a lateral area 102 b (whichspans the sides and undersides of the bra cup 104) of the bra cup 104and a peripheral area 102 c (which spans outside of the bra cups 104).An intermediate bridge region 106 may extend between the two bra cups104. In the preferred form, at least one of the material components ofthe bra cup region 102 is continuous throughout therein and preferablyalso over the bridge region 106. However, in alternative forms each ofthe bra cups 104 may be separately predefined and may be affixedtogether at the bridge region 106 to define, once assembled, a bra cupregion 102. In some examples, the bra cup region 102 may be seamless andmade from materials at least some of which are molded and that areengaged to each other preferably at least in part by lamination. Thebrassiere 100 may further include elements, such as shoulder straps 108,chest bands 110, etc. for supporting the brassiere 100 against the bodyof the wearer, when worn.

In one embodiment of the present disclosure, the bra cup 104 is amulti-layer structure. FIG. 2A illustrates a diagrammatic view of thebra cup 104 and FIG. 2B illustrates a partial side edge view of the bracup 104, of FIG. 1. As illustrated more clearly in FIG. 2B, the bra cup104 includes three layers; a core layer 112, an inner layer 114 and anouter layer 116. As may be seen, the core layer 112 is disposed betweenthe inner layer 114 and the outer layer 116, in the bra cup 104. Thethree layers 112, 114, 116 are arranged such that the inner layer 114 isdisposed to be in contact with a breast of a wearer and the outer layer116 is located at a distal end from the breast of the wearer, when thebrassiere 100 is worn. The core layer 112 have an inner side 112 a (asillustrated more clearly in FIG. 3B) which is disposed in contact withthe inner layer 114 and an outer side 112 b (as illustrated in moreclearly FIG. 3A) which is disposed in contact with the outer layer 116,when the brassiere 100 is in its completed form. In general, asillustrated in the associated drawings, the core layer 112 has athree-dimensional configuration, such that the bra cup 104 has agenerally concave shape when viewed with respect to the inner layer 114in front and a generally convex shape when viewed with respect to theouter layer 116 in front.

In the brassiere 100, the core layer 112 is made of foam material. Thefoam material provides the flexibility to the core layer 112, andthereby the bra cup 104 which is required for conforming to the breastof the wearer, when the brassiere 100 is worn. In one or moreembodiments, the foam material includes one of polyurethane-basedmaterial, silicone-based material, latex-based material and rubber-basedmaterial. Preferably, the foam material includes one of thermoplasticrubber (TPR), thermoplastic polyurethane (TPU), silicone, ethylene vinylacetate (EVA), polyvinyl chloride (PVC) and polypropylene (PP). Further,in one embodiment, both of the inner layer 114 and the outer layer 116includes a fabric sheet (not shown). In other embodiments, both of theinner layer 114 and the outer layer 116 includes a fabric sheet (notshown) and a foam sheet (not shown). In such case, the fabric sheet andthe foam sheet may be laminated and co-extensive with each other. Theinner layer 114 and the outer layer 116 are arranged with respect to thecore layer 112 such that the foam sheets thereof are in contact with theinner side 112 a and the outer side 112 b of the core layer 112 andthereby the fabric sheets thereof form the exterior surfaces of the bracup 104, when the brassiere 100 is in its completed form.

In one example, the fabric sheets may be a product known by model numberCMF-7440MU of Friendly Foundate Ltd. and having a make-up ofapproximately 80% Tactel and 20% Lycra, and of a weight of, for example,about 190 g/sqm. Further, the foam sheets are preferably of apolyurethane foam such as, for example, EL58-4S of Inoac Corporationwhich is a memory foam. In some examples, the fabric sheet and the foamsheet of the corresponding layer may be laminated together using anadhesive, such as glue HM-1 of Forbo Swift Adhesives SA. The adhesivemay be sprayed onto at least one of the opposing facing surfaces of thefabric sheet and the foam sheet. The adhesive may stick the fabric sheetand the foam sheet together when dry without heating, to form thecorresponding panels for the inner layer 114 and the outer layer 116.

Further, as illustrated in FIGS. 2A-2B, the bra cup 104 includes a mesh118, such as a mesh fabric, joined with the core layer 112. In someexamples, the mesh 118 is formed with the core layer 112 in theinjection molding process (as will be discussed later). The mesh 118provides support to the core layer 112 and prevent breaking of the corelayer 112 during the said injection molding process. In the illustratedexample, the mesh 118 is shown to be provided between the core layer 112and the outer layer 116; however, in other examples, the mesh 118 may beprovided between the core layer 112 and the inner layer 114 withoutaffecting the scope of the present disclosure. In some other examples,the bra cup 104 may have two meshes 118 provided between the core layer112 and the outer layer 116, as well as between the core layer 112 andthe inner layer 114. Furthermore, as illustrated in FIGS. 2A-2B, the bracup 104 also includes an underwire 120 embedded within the core layer112. In one or more examples, the underwire 120 may generally be aU-shaped wire. The underwire 120, in each bra cup 104, may help to shapeand support lower periphery of the corresponding bra cup 104, in thecore layer 112. The underwire 120 is made either of metallic material orplastic material, like a rigid plastic material.

FIGS. 3A-3B illustrate front and back views of the core layer 112,respectively, spanning the entire bra cup region 102, according to afirst embodiment of the present disclosure. It may be contemplated thatalthough the core layer 112 is shown spanning the entire bra cup region102; in other examples, the core layer 112 may be spanning only one ofthe bra cup 104, and the two such core layers for respective two bracups 104 may be joined together later to define the bra cup region 102,without any limitations. As illustrated in FIGS. 3A-3B, each of the bracups 104 includes a plurality of apertures (generally designated by thenumeral 122) formed in the core layer 112. In one or more examples, theplurality of apertures 122 are circular apertures in the form ofcircular holes formed in the core layer 112. In other examples, theapertures 122 may have different shapes, such as but not limited to,elliptical, triangular, hexagonal, square, rectangular, or the likewithout any limitations. Further, in one or more examples, one or moreof the apertures 132 have a truncated cross-section, similar to theapertures 122 in the lower portion 102 d of the lateral area 102 b ofthe bra cup 104, as discussed in reference to FIGS. 3A-3C. As may beseen, the plurality of apertures 122 may be disposed radially outwardsfrom the center ‘C’ of the bra cup 104 (which is also an apex thereof).As illustrated in FIGS. 3A-3B, the plurality of apertures 122 are formedboth in the frontal area 102 a and the lateral area 102 b of the bra cup104. In one or more embodiments, the bra cup 104 have a denserconcentration of the apertures 122 around the center ‘C’, and theconcentration of the apertures 122 may start decreasing in a regular orirregular manner moving radially away from the center ‘C’. As may beseen, the bra cup 104 may generally have a relatively largerconcentration of the apertures 122 in the frontal area 102 a as comparedto the lateral area 102 b. In one or more examples, the peripheral area102 c also has apertures 122 formed therein.

In the present embodiment, the apertures 122 formed in the lateral area102 b of the bra cup 104 in the core layer 112 have a truncated conicalcross-section, while the apertures 122 formed in the frontal area 102 aof the bra cup 104 in the core layer 112 have a substantiallycylindrical cross-section. In other words, the apertures 122 formed inthe lateral area 102 b have a relatively larger diameter towards theinner side 112 a of the core layer 112 and a relatively smaller diametertowards the outer side 112 b of the core layer 112. In one or moreembodiments, only the apertures 122 formed in a lower portion (generallyshown with numeral 102 d in FIGS. 3A-3C) of the lateral area 102 b ofthe bra cup 104 have the truncated conical cross-section. That is, atleast one of the apertures 122 in the lower portion 102 d of the lateralarea 102 b has a larger diameter at the inner side 112 a as compared tothe same aperture 122 at the outer side 112 b. This implies that theapertures 122 in the lower portion 102 d of the lateral area 102 b atthe inner side 112 a being generally larger than the apertures 122 inthe frontal area 102 a at the inner side 112 a; whereas the apertures122 at the outer side 112 b are generally even-sized. This is donebecause larger diameter apertures are not desirable on the outer side112 b, as it is preferable to have a smooth outlook of the bra cup 104from the outside, and thus even-sized apertures 122 are providedtherein. Further, it may be contemplated that in case the apertures 122have larger diameter at the outer side 112 b, it may possibly render thebra cup 104 as see-through, which is again not desirable.

FIG. 3C illustrates a cross-section view of the bra cup 104 of FIGS.3A-3B taken along a line A-A′ of the core layer 112 of FIG. 3A. As mayfurther be seen from the section view of FIG. 3C, the apertures 122 inthe lower portion 102 d of the lateral area 102 b have the truncatedconical shape between the inner side 112 a and the outer side 112 b. Itmay be appreciated by a person skilled in the art that the lower portion102 d of the lateral area 102 b of the bra cup 104 is generally tightlyfit to the breast of the wearer, and thus may possibly develop andaccumulate more sweat from the breast of the wearer, when the brassiere100 is worn. The larger diameter of the apertures 122 at the inner side112 a of the core layer 112 aids with improving ventilation around thelower portion 102 d of the lateral area 102 b of the bra cup 104 tomitigate such issues to some extent. As a result, the truncated conicalcross-section of the apertures 122 may help with providing some reliefto the wearer by improving ventilation and thus enhances the comfort tothe wearer, when the brassiere 100 is worn. Furthermore, the truncatedconical cross-section of the apertures 122 in the core layer 112 reducesthe amount of the foam material that may be required for forming thecore layer 112, and may thus reduce the cost of manufacturing the corelayer 112 for the present brassiere 100.

FIGS. 4A-4B illustrate front and back views of the core layer 112,respectively, spanning the entire bra cup region 102, according to asecond embodiment of the present disclosure. It may be contemplated thatalthough the core layer 112 is shown spanning the entire bra cup region102; in other examples, the core layer 112 may be spanning only one ofthe bra cup 104, and the two such core layers for respective two bracups 104 may be joined together later to define the bra cup region 102,without any limitations. In the present embodiment, the plurality ofapertures 122 formed in the core layer 112 of the bra cup 104 includes aplurality of circular apertures 124 and a plurality of elongatedapertures 126. In some examples, the circular apertures 124 maygenerally be in the form of holes formed in the core layer 112 and theelongated apertures 126 may generally be in the form of slits formed inthe core layer 112. In one or more examples, the circular apertures 124are formed generally in the lateral area 102 b of the bra cup 104 andthe elongated apertures 126 are formed generally in the frontal area 102a of the bra cup 104.

As may be seen in FIGS. 4A-4B, the elongated apertures 126 are disposedsubstantially in a circular fashion around the center ‘C’ of each of thebra cup 104. In particular, the elongated apertures 126 may be arrangedalong one or more circular tracks of different diameters around thecenter ‘C’ of each of the bra cup 104. Specifically, the elongatedapertures 126 may be so arranged such that the slits formed in the corelayer 112 are generally extending along a longitudinal direction ‘X’ ofthe bra cup 104 and thereby allow for expansion of the bra cup 104 alonga lateral axis ‘Y’ thereof. Such lateral expansion of the bra cup 104allows the bra cup 104 to expand (if needed) and conform to the shape ofthe breast of the wearer with relatively much ease, when the brassiere100 is worn. Further, in one or more examples, one or more of thecircular apertures 124 have a truncated cross-section, similar to theapertures 122 in the lower portion 102 d of the lateral area 102 b ofthe bra cup 104, as discussed in reference to FIGS. 3A-3C.

FIGS. 5A-5B illustrate front and back views of the core layer 112,respectively, spanning the entire bra cup region 102, according to athird embodiment of the present disclosure. It may be contemplated thatalthough the core layer 112 is shown spanning the entire bra cup region102; in other examples, the core layer 112 may be spanning only one ofthe bra cup 104, and the two such core layers for respective two bracups 104 may be joined together later to define the bra cup region 102,without any limitations. In the present embodiment, the plurality ofapertures 122 formed in the core layer 112 of the bra cup 104 includes aplurality of circular apertures 128 and a plurality of elongatedapertures 130. In some examples, the circular apertures 128 maygenerally be in the form of holes formed in the core layer 112. In thepresent embodiment, as illustrated in FIGS. 5A-5B, one or more of theelongated apertures 130 have a dumbbell shape with a slit 130 a, and twoopenings 130 b formed at two ends of the slits 130 a respectively. Inone or more examples, the circular apertures 128 are formed in thelateral area 102 b of the bra cup 104 and the elongated apertures 130are formed in the frontal area 102 a of the bra cup 104.

As may be seen in FIGS. 5A-5B, the elongated apertures 130 are disposedsubstantially in a circular fashion around the center ‘C’ of each of thebra cup 104. In particular, the elongated apertures 130 may be arrangedalong one or more circular tracks of different diameters around thecenter ‘C’ of each of the bra cup 104, such that each of the one or moreof the plurality of elongated apertures 130 allows for expansion of thecore layer 112 along a direction substantially orthogonal to a directionof extension of the corresponding slit 130 a in the core layer 112.Specifically, the elongated apertures 130 may be so arranged such thatthe slits 130 a formed in the core layer 112 are generally extendingalong the longitudinal direction ‘X’ of the bra cup 104 and therebyallow for expansion of the bra cup 104 generally along the lateral axis‘Y’ thereof. Such lateral expansion of the bra cup 104 allows the bracup 104 to expand (if needed) and conform to the shape of the breast ofthe wearer with relatively much ease, when the brassiere 100 is worn.Furthermore, the openings 130 b in the elongated apertures 130 allowsfor enhanced ventilation from the elongated apertures 130 around thefrontal area 102 a in comparison to the elongated apertures 126 of thebra cup 104 of FIGS. 4A-4B. As may be understood, this improvedventilation may result in enhanced comfort to the wearer, when thebrassiere 100 is worn. Further, in one or more examples, one or more ofthe circular apertures 128 have a truncated cross-section, similar tothe apertures 122 in the lower portion 102 d of the lateral area 102 bof the bra cup 104, as discussed in reference to FIGS. 3A-3C.

FIGS. 6A-6B illustrate front and back views of the core layer 112,respectively, spanning the entire bra cup region 102, according to afourth embodiment of the present disclosure. It may be contemplated thatalthough the core layer 112 is shown spanning the entire bra cup region102; in other examples, the core layer 112 may be spanning only one ofthe bra cup 104, and the two such core layers for respective two bracups 104 may be joined together later to define the bra cup region 102,without any limitations. Further, it may be contemplated that althoughthe outline of the bra cup region 102 is shown different in FIGS. 6A-6Bas compared to FIGS. 3A-5B; in other examples, it may have similaroutline without affecting the scope of the present disclosure in anymanner. As illustrated in FIGS. 6A-6B, each of the bra cups 104 includesa plurality of apertures 132 formed in the core layer 112. In one ormore examples, the plurality of apertures 132 are circular apertures inthe form of holes formed in the core layer 112. The apertures 132 extendbetween the inner side 112 a and the outer side 112 b of the core layer112. Further, as illustrated better in FIG. 6B, the bra cup 104 includesa plurality of protrusions 134 defined in the core layer 112 towards theinner side 112 a thereof. As may be seen from FIG. 6B, the apertures 132and the protrusions 134 are arranged individualistically at the innerside 112 a of the core layer 112.

FIG. 6C illustrates a cross-section view of the bra cup 104 taken alonga line B-B′ of FIG. 6A. As may be seen more clearly from FIG. 6C, theprotrusions 134 may be defined by forming multiple grooves 136 in theinner side 112 a of the core layer 112. The apertures 132 are generallydisposed within the grooves 136 at the inner side 112 a of the corelayer 112. In one or more embodiments, the protrusions 134 are arrangedin a matrix form such that one or more of the plurality of apertures 132are surrounded by three or more protrusions 134 at the inner side 112 aof the core layer 112. In the illustrated examples, the apertures 132are disposed between two protrusions 134 in one direction, and betweentwo other protrusions 134 in another direction. For this purpose, theprotrusions 134 may be defined by forming two groups such that thegrooves 136 in the same group are disposed parallel to each other andthe grooves 136 in different groups are running in orthogonal directionswith respect to each other, in the inner side 112 a of the core layer112. In other examples, the protrusions 134 may be arranged in acircular manner around the center ‘C’ or in a radial manner from thecenter ‘C’, without any limitations.

In one or more embodiments, the plurality of protrusions 134 includes afirst set of protrusions 134 a with substantially square shape and asecond set of protrusions 134 b with substantially parallelogram orrhombus shape, such that the first set of protrusions 134 a are disposedproximal to the bridge region 106 of the bra cup 104 in the core layer112 (i.e. towards a middle of the bra cup region 102) and the second setof protrusions 134 b are disposed away from the bridge region 106 of thebra cup 104 in the core layer 112 (i.e. towards edges of the bra cupregion 102). It may be understood that the change in shape of theprotrusions 134 as moving away from the bridge region 106 of the bra cup104 provides better fit of the bra cup 104 (with the three-dimensionalconfiguration of the core layer 112) over the breast of the wearer, whenthe brassiere 100 is worn. In other examples, the protrusions 134 mayhave different shapes, such as but not limited to, circular, elliptical,triangular, hexagonal, or the like without any limitations. Further, inone or more examples, one or more of the apertures 132 have a truncatedcross-section, similar to the apertures 122 in the lower portion 102 dof the lateral area 102 b of the bra cup 104, as discussed in referenceto FIGS. 3A-3C.

It may be understood that a top of the protrusion 134 is in contact withthe inner layer 114, when the brassiere 100 is in its completed form.Further, the ventilation space is created where protrusions 134 areabsent; that is, in the grooves 136 at the inner side 112 a of the corelayer 112. The protrusions 134 in the core layer 112 further result inless material being used for the core layer 112 (due to the grooves 136formed therein), which results in reduced weight of the core layer 112and hence of the bra cup 104, without compromising the support providedto the breasts of the wearer, when the brassiere 100 is worn. As betterillustrated in FIG. 6B, the peripheral area 102 c of the bra cup region102 may not have the protrusions 134 defined therein. In some examples,the peripheral area 102 c flushes with the top of the protrusions 134 atthe inner side 112 a to provide a substantially smooth profile on theinner side 112 a of the core layer 112.

In one or more embodiments of the present disclosure, the three layers112, 114, 116 are either loose with respect to each other or affixed toeach other. Preferably, the three layers 112, 114, 116 are moldedtogether using known heat molding techniques involving the applicationof heat and pressure to form the bra cup 104. The core layer 112, theinner layer 114 and the outer layer 116 may be separately pre-molded andlater joined together to form the bra cup 104. In one or more examples,the three layers 112, 114, 116 may be bonded or laminated during themolding process simply by the application of heat and pressure, or mayadditionally involve the use of an adhesive to facilitate bonding of thelayers. The employed bonding techniques may depend largely on the natureof the various layers. In one example, the adhesive may be a glue suchas RM-30 of Ultra Energy Adhesive Trading Co., Ltd. The adhesive may besprayed on the inner side 112 a and the outer side 112 b of the corelayer 112 and the corresponding facing surfaces of the inner layer 114and the outer layer 116. The molding process may involve use of heat andpressure for joining together the three layers 112, 114, 116 together,and further aid with drying of the adhesive glue. For example, thisadhesive may not get dry and sticky until heated, but then stick to jointhe three layers 112, 114, 116 when heated during the molding process.Further, the three layers 112, 114, 116 may be joined together byultrasonic welding or the like. The following paragraphs explain indetail the molding setup and process for forming the core layer 112 (inaccordance with the said third embodiment of FIGS. 5A-5C) with the shapeof the bra cup 104 defined therein.

FIG. 7 illustrates a molding arrangement 700 for forming the core layer112 of the bra cup 104. As illustrated, the molding arrangement 700includes a first mold 702 and a second mold 704. As discussed, the corelayer 112 is formed of the foam material, such as, for example, apolyurethane foam. In an embodiment, the core layer 112 is formed byinjection molding process. For this purpose, the foam material in liquidform, and in appropriate quantity, is injected into a cavity between thefirst mold 702 and the second mold 704. The injection molding process offoam materials and the required parameters thereof are well known in theart and thus have not been described herein for the brevity of thepresent disclosure. The injection molding of the foam material forms apanel (not shown) with the core layer 112 having the desiredthree-dimensional configuration being a part thereof. Therefrom, thecore layer 112 may be obtained by trimming the edges of such formedpanel. As illustrated in FIG. 7, the first mold 702 and the second mold704 may have projections 706 defined therein. These projections 706 mayinclude one or more of cylindrical projections 706 a and elongatedprojections 706 b. In some examples, the elongated projections 706 b mayhave a dumbbell shape. It may be contemplated by a person skilled in theart that the cylindrical projections 706 a may define the complementarycircular apertures, such as the circular apertures 128, and theelongated projections 706 b may define the complementary elongatedapertures, such as the elongated apertures 130, in the molded core layer112.

In some embodiments, as illustrated, the mesh 118 may be placed betweenthe first mold 702 and the second mold 704 so that the mesh 118 may beintegrally formed with the core layer 112. For this purpose, the mesh118 may be supported in a frame 708 to be kept stretched during themolding process. Further, one or more first anchors 710 may be providedwith one or more of the first mold 702 and the second mold 704 tomaintain a gap (generally equivalent to a thickness of the core layer112) with one of the first mold 702 and the second mold 704, such thatthe mesh 118 is formed with one of the inner side 112 a and the outerside 112 b (as desired), when the foam material is cured. It may beunderstood that the mesh 118 helps with curing of the foam material intothe shape of the core layer 112 without breaking. In some embodiments,as illustrated, the underwire 120 is supported on one or more secondanchors 712 provided with either the first mold 702 or the second mold704 (shown with the second mold 704 in the illustrated example) at aheight (generally equivalent to half of a thickness of the core layer112) so that the underwire 120 is embedded within the core layer 112,when the foam material is cured.

It may be contemplated by a person skilled in the art that the corelayer 112 as provided in other above-mentioned embodiments (such as, forexample, in reference to FIGS. 3A-3B, 4A-4B and 6A-6B) may bemanufactured using slightly different molding arrangements (as comparedto the molding arrangement 700); in particular, by having differenttypes of projections 706 defined therein. For example, the core layer ofFIGS. 6A-6C may be formed by using a molding arrangement withprojections in the form of ridges to define the protrusions 134 therein.In one or more examples, the thickness of the formed core layer 112 isgenerally equal to the sum of the thicknesses of a base of the corelayer 112, the protrusion 134 and the mesh 118. Exemplarily, the base ofthe core layer 112 has a thickness of 0.2 mm, the protrusion 134 has athickness of 0.6 mm and the mesh 118 has a thickness of 0.2 mm, andtherefore the thickness of the core layer 112 is about 1 mm. Additionalcomponents, layers or plies of material may be provided with thematerials defining the bra cup region 102 and/or the bra cup 104, tothose herein defined.

In the present brassiere 100, the bra cup 104 with apertures andprotrusions formed in the core layer 112 thereof enhances theventilation and air permeability of the bra cup 104. In addition, thebra cup 104 of the present disclosure with multi-layer structureprovides higher deformability to conform to varying sized and shapedbreasts, as compared to bra cup with a single thin foam layer asconventionally known in the art. The bra cup 104 being primarily formedfrom the foam material and generally light fabric sheets may belight-weight, and thus make the present brassiere 100 light incomparison to conventional brassieres. Therefore, the present brassiere100 may provide enhanced comfort to the wearer, when worn. The presentbra cup 104 further evenly distributes pressure caused by the weight ofthe brassiere 100 to the breasts of the wearer, thereby furtherenhancing comfort during long use.

Molding of the bra cup 104 may substantially simplify the otherwisecomplicated process of stitching various layers together. The bra cup104 may be manufactured substantially without or with no significantstitching. This may result in significant savings in labor cost whichmay otherwise be needed for manual stitching of the various layerstogether. The implementation of injection molding for forming the corelayer 112 results in even distribution of the foam material in the corelayer 112 between thin and thick sections of the bra cup 104. This evendensity distribution of the foam material in the core layer 112 mayenhance the stability of the overall brassiere 100, when worn. Thisfurther enhances the ability of the bra cup 104 to absorb impacts,including torsional and compressive forces. The fabric sheets of theinner layer 114 and the outer layer 116, which form the exterior surfaceof the bra cup 104, may provide breathable material in contact with theskin of the wearer, when the brassiere 100 is worn. This may help toabsorb and disperse moisture from the skin to some extent, therebyfurther enhancing comfort for the wearer. Such fabric sheets may furtherbe formulated with anti-microbial chemicals, which may improve hygieneconditions.

The foregoing descriptions of specific embodiments of the presentdisclosure have been presented for purposes of illustration anddescription. They are not intended to be exhaustive or to limit thepresent disclosure to the precise forms disclosed, and obviously manymodifications and variations are possible in light of the aboveteaching. The exemplary embodiment was chosen and described in order tobest explain the principles of the present disclosure and its practicalapplication, to thereby enable others skilled in the art to best utilizethe present disclosure and various embodiments with variousmodifications as are suited to the particular use contemplated.

1. A bra cup for a brassiere to be worn by a wearer, the bra cupcomprising: a core layer formed of a foam material and having athree-dimensional configuration so as to conform to a breast of thewearer when the brassiere is worn, the core layer having an inner sideand an outer side; and a plurality of apertures formed in the corelayer, wherein the plurality of apertures comprises a plurality ofcircular holes and a plurality of elongated apertures; wherein one ormore of the plurality of circular holes have a truncated conicalcross-section with a relatively larger diameter towards the inner sideand a relatively smaller diameter towards the outer side, of the corelayer; wherein the plurality of circular holes are formed in a lateralarea of the bra cup, and the plurality of elongated apertures are formedin a frontal area of the bra cup; and wherein one or more of theplurality of circular holes in a lower portion of the lateral area havethe truncated conical cross-section.
 2. (canceled)
 3. The bra cup asclaimed in claim 1, wherein one or more of the plurality of elongatedapertures have a dumbbell shape with a slit and two openings formed attwo ends of the slits respectively.
 4. The bra cup as claimed in claim 1further comprising a plurality of protrusions defined in the core layertowards the inner side thereof, wherein the protrusions are arranged ina matrix form such that one or more of the plurality of apertures aresurrounded by three or more protrusions at the inner side of the corelayer.
 5. The bra cup as claimed in claim 4, wherein the plurality ofprotrusions comprises a first set of protrusions with substantiallysquare shape and a second set of protrusions with substantiallyparallelogram shape, and wherein the first set of protrusions arelocated in a frontal area of the bra cup and the second set ofprotrusions are located in a lateral area of the bra cup.
 6. The bra cupas claimed in claim 1, wherein the core layer and the plurality ofapertures therein are formed by an injection molding process.
 7. The bracup as claimed in claim 6 further comprising a mesh joined with the corelayer in the injection molding process.
 8. The bra cup as claimed inclaim 1 further comprising an underwire embedded within the core layer.9. The bra cup as claimed in claim 8, wherein the underwire is madeeither of metallic material or plastic material.
 10. The bra cup asclaimed in claim 1 further comprising: an inner layer comprising atleast a fabric sheet and optionally a foam sheet, and arranged withrespect to the core layer such that the inner layer is disposed to be incontact with the breast of the wearer, when the brassiere is worn; andan outer layer comprising at least a fabric sheet and optionally a foamsheet, and arranged with respect to the core layer such that the outerlayer is located at a distal end from the breast of the wearer, when thebrassiere is worn.
 11. A method of manufacturing a bra cup for abrassiere, the method comprising: providing a foam material in liquidform; providing a mold arrangement comprising a first mold and a secondmold, at least one of the first mold and the second mold having aplurality of projections defined therein; injecting the foam materialinto the mold arrangement between the first mold and the second mold;and curing the foam material to be contoured into a three-dimensionalconfiguration to form a core layer of the bra cup with a plurality ofapertures, complementary to the plurality of projections, formedtherein, wherein one or more of the plurality of apertures have atruncated conical cross-section with a relatively larger diametertowards the inner side and a relatively smaller diameter towards theouter side, of the core layer; wherein the plurality of aperturescomprises: a plurality of elongated apertures disposed in a frontal areaof the bra cup; and a plurality of circular holes disposed in a lateralarea of the bra cup, wherein one or more of the plurality of circularholes in a lower portion of the lateral area have the truncated conicalcross-section.
 12. (canceled)
 13. The method as claimed in claim 11,wherein one or more of the plurality of elongated apertures have adumbbell shape with a slit and two openings formed at two ends of theslits respectively.
 14. (canceled)
 15. The method as claimed in claim 11further comprising: providing a mesh; and supporting the mesh on one ormore first anchors between the first mold and the second mold during theinjection of the foam material, such that the mesh is joined with thecore layer from at least one of an inner side and an outer side thereofwhen the foam material is cured.
 16. The method as claimed in claim 11further comprising: providing an underwire; and supporting the underwireon one or more second anchors between the first mold and the second moldduring the injection of the foam material, such that the underwire isembedded within the core layer when the foam material is cured.
 17. Themethod as claimed in claim 11, further comprising: providing a fabricsheet which is to be part of an inner layer of the bra cup; andproviding a fabric sheet which is to be part of an outer layer of thebra cup; wherein the foam material is injected between the fabric sheetof the inner layer and the fabric sheet of the outer layer such that theformed core layer is joined therewith when the foam material is cured.18. A bra cup for a brassiere to be worn by a wearer, the bra cupcomprising: a core layer formed of a foam material and having athree-dimensional configuration so as to conform to a breast of thewearer when the brassiere is worn, the core layer having an inner sideand an outer side; a plurality of apertures formed in the core layer,the plurality of apertures extending between the inner side and theouter side of the core layer; and a plurality of protrusions defined inthe core layer towards the inner side thereof, wherein the protrusionsare arranged in a matrix form such that one or more of the plurality ofapertures are surrounded by three or more protrusions at the inner sideof the core layer; wherein the plurality of apertures comprises: aplurality of elongated apertures formed in a frontal area of the bracup; and a plurality of circular holes formed in a lateral area of thebra cup wherein one or more of the plurality of elongated apertures havea dumbbell shape with a slit and two openings formed at two ends of theslits respectively, such that each of the one or more of the pluralityof elongated apertures allows for expansion of the core layer along adirection substantially orthogonal to a direction of extension of thecorresponding slit therein; and wherein one or more of the plurality ofcircular holes in a lower portion of the lateral area have a truncatedconical cross-section with a relatively larger diameter towards theinner side of the core layer and a relatively smaller diameter towardsthe outer side of the core layer. 19-21. (canceled)
 22. The bra cup asclaimed in claim 18, wherein the plurality of protrusions comprises afirst set of protrusions with substantially square shape and a secondset of protrusions with substantially parallelogram shape, and whereinthe first set of protrusions are located in a frontal area of the bracup and the second set of protrusions are located in a lateral area ofthe bra cup.